Danfoss GD30FDC User manual

Danfoss Light Commercial
Refrigeration Compressors
GD30FDC
Electronic driver connection manual, 12-42V, Direct Current - R134a
Installation guide
lightcommercialrefrigeration.danfoss.com

Content
Wiring and Connections ......................................................................................................4
Setting up the speed............................................................................................................6
Operating voltage................................................................................................................8
Battery protection system ..................................................................................................9
Protections and alarms......................................................................................................10
3FRCC.PI.045.A1.02

Wiring and Connections
GD30FDC must always be powered through
the dedicated electronic driver FDC1, which
is supplied with the compressor as a separate
device.
NEVER CONNECT THE COMPRESSOR’S HERMETIC
PINS (FUSITE) TO THE TERMINALS OF A BATTERY
OR ANY OTHER DC OR AC SOURCE DIRECTLY.
DO NOT TRY TO FIT AN ELECTRONIC DRIVER
OTHER THAN THE FDC1. THE COMPRESSOR WILL
NOT OPERATE AND IRREVERSIBLE DAMAGE MAY
OCCUR.
The FDC1 driver is directly connected to the
battery poles as well as to the compressor pins.
It checks battery voltage and adjusts itself to the
voltage value for proper compressor operation,
or switches itself o if the battery voltage is not
adequate. The driver also controls the compressor
speed.
ALWAYS RESPECT THE POLARITY OF THE BATTERY
WITH THE POWER INPUT TERMINALS OF THE
ELECTRONIC DRIVER.
The unit is protected against damage caused by
wrong polarity of the supply. The compressor will
not run correctly if it’s wrongly connected.
THE POWER INPUT TERMINAL “-“ OF THE
ELECTRONIC DRIVER SHOULD BE REFERRED TO
THE CHASSIS OF THE VEHICLE AS WELL AS THE
APPLIANCE FRAME*
A FUSE MUST BE PLACED BETWEEN THE “+” POLE
OF THE BATTERY OR DC POWER SUPPLY, AND THE
“+” POWER INPUT TERMINAL OF THE ELECTRONIC
DRIVER
12V SYSTEMS: 30A FUSE
24V SYSTEMS: 15A FUSE
42V SYSTEMS: 10A FUSE
In some special vehicles, the chassis is connected
to“+” terminal of the battery instead of“-“
terminal (positive reference systems). In such
cases,“+” should be understood as “-“ and
vice-versa.
In systems powered by a variable DC source, the
fuse should be selected following the rules above
mentioned, considering the maximum voltage at
the variable DC Source.
To avoid excessive voltage drop in the leads, their
length and cross section must be related to the
voltage supply, as indicated in Table 1.
If any kind of connector or switch is placed
between the battery poles and the power
terminals of the electronic driver, its resistance
should be less than 10mΩ. If the resistance is
higher than 5mΩ, the maximum length of the
wires indicated in Table 1 should be halved or the
cross section should be doubled.
General rules
Voltage drop in the
power leads
Cross section mm2Rated Operating Range
12 - 14 V 24 - 28 V 36 - 42 V
2.5 1.5 3 4.5
4 2.5 5 7.5
6 4 8 12
10 6 12 18
Table 1: Maximum length
of leads (m)
4FRCC.PI.045.A1.02

Wiring and Connections
The FDC1 electronic driver features a terminal
board where all connections are made. The
terminal lay out is described in Figure 1:
Wiring Diagram
FUSE
12÷42V
BATTERY
FAN
THERMOSTAT
ELECTROMECHANICAL
OR ELECTRONIC
PC
ELECTRONIC INTEGRAL MANAGER
CONTROL PANEL
SPI
FDC1/FDC3
ELECTRONIC DRIVER
Fig 1. FDC1 Wiring
scheme
NO RESISTOR IS NEEDED TO BE INSTALLED IN
FDC1 ELECTRONIC DRIVER
When connecting the electronic driver to the
compressor, any position of the connector
is possible under an electrical point of view.
However, in practice, the vertical position is not
possible because the electronic box cannot be
assembled. The connector should be rotated 120°
clockwise or counter clockwise with respect to
the vertical position as shown below.
Fig 2. Connection of the
FDC’s electronic driver to
the compressor
5FRCC.PI.045.A1.02

Setting up the speed
The electronic control unit FDC1 is supplied
with the exclusive Serial Port Interface (SPI),
featuring a RJ11 telephone type connector. This
port is congured to set up the compressor
speed through physical connections between
their terminals. To facilitate this procedure, three
connector cables are supplied together with the
electronic driver. The compressor will run at a
certain speed depending on the used connector,
as shown in Table 2:
Furthermore, if a FDC programming kit is
available, the new FDC1 electronic driver can
be set up by programming it using the kit and a
computer.
NEVER USE FDC1 ELECTRONIC DRIVER IN OTHER
DC COMPRESSOR DIFFERENT THAN GD30FDC.
If the compressor or the FDC1 electronic driver
should be replaced for servicing a refrigerator or
a freezer, one of the next procedures should be
followed.
1. If a FDC programming kit is available, use it
to check the settings of the old FDC1 electronic
driver and set up the new one by programming
the same parameters.
2. Otherwise, check the old FDC1 electronic driver
for the presence of a connector at the SPI to set
up the speed. If so, take it away and connect it
again at the new FDC1 electronic driver.
3. Otherwise check the appliance for some
information about compressor speed set up. If
so, select the proper connector which gives the
nearest speed set up from table 2.
4. Otherwise compressor speed can be set up by
a trial and error procedure. In this case, take as a
rst approximation the connectors indicated in
table 3 depending on the type of appliance and
its net volume.
1. Check the compressor model and speed.
2. If speed S0is known and a FDC programming
kit is available, set up GD30FDC compressor
speed by programming the following speed:
S = S0/ 1.5 for BD35F
S = S0/ 1.2 for BD50F
S = S0for BD80F
3. Otherwise, set up GD30FDC compressor speed
according to Table 4.
Table 2. Compressor
speed for each connector
Replacing a GD30FDC
compressor or FDC1
electronic driver
Replacing a DC
compressor model
BD35F, BD50F or BD80F
4. If speed is not known, measure the value of the
resistor R1 placed in series with the thermostat
and connected to“C”terminal. Then set up
GD30FDC speed according to Table 5.
Connector Speed
NONE 1.500
BLACK 2.167
BLUE 2.833
RED 3.500
Connector Refrigerator Freezer Refrigerator + freezer
None less than 60 liters less than 40 liters less than 50 liters
Black from 60 to 150 liters from 40 to 100 liters from 50 to 125 liters
Blue from 120 to 300 liters from 80 to 200 liters from 100 to 250 liters
Red from 180 to 450 liters from 120 to 300 liters from 150 to 375 liters
Compressor Without connector Black connector Blue connector Red connector
BD35F rpm < 2.750 rpm >2.750 - -
BD50F rpm < 2.200 rpm = 2.200 a 3.000 rpm > 3.000 -
BD80F - rpm < 2.500 rpm = 2.500 a 3.150 rpm > 3.150
Table 3. Suggested
connector as a the
function of the appliance
Table 4. Type of
connector to be used to
replace Danfoss
compressor when speed
is known
6FRCC.PI.045.A1.02

1. Check for compressor displacement D0and
Speed S0. Then calculate the required velocity of
GD30FDC as follows:
S = D0· S0/ 3 ( D0in cm3)
and set up GD30FDC speed by programming (if
FDC programming kit is available) or by selecting
a proper connector according to Table 2.
2. If any parameter, displacement or speed is
unknown, GD30FDC compressor speed can be
set up by a trial an error procedure. In this case,
try the connectors shown in Table 3 depending
on the type of appliance and its net volume.
Replacing a dierent
brand DC compressor
Setting up the speed
Compressor Without connector Black connector Blue connector Red connector
BD35F R1 < 450 Ω R1 > 450 Ω - -
BD35F with AEO R1 < 623 Ω R1 > 623 Ω - -
BD50F R1 < 112 Ω R1 = 112 to 692 Ω R1 > 692 Ω -
BD50F with AEO R1 < 285 Ω R1 = 285 to 865 Ω R1 > 865 Ω -
BD80F with AEO - R1 < 173 Ω R1 = 173 to 471 Ω R1 > 471 Ω
Table 5. Connector to be
used to replace Danfoss
compressor when R1
resistor is known
7FRCC.PI.045.A1.02

Operating voltage
GD30FDC is designed to operate in a wide range
of DC voltages, supplied either by a battery or by
any other kind of ltered DC power supply.
DC VOLTAGE SUPPLY ALLOWED is 10V to 42.4V
From the value of the applied voltage, the
electronic driver automatically decides the rated
voltage range of the supply. Three possible
ranges are considered:
12 to 14V: voltage is below 17V
24 to 28V: voltage is within 17 and 33V
36 to 42V: voltage is within 33 and 42.4V
8FRCC.PI.045.A1.02

There is a protection system for the battery
that prevents the compressor from operating if
the available voltage becomes too low. Battery
protection level is set up for working under
normal circumstances in most appliances. Cut-
out and cut-in values are:
12V system: cut-out = 10.0V; cut-in = 11.5V
24V system: cut-out = 22.0V; cut-in = 24.5V
42V system: cut-out = 36.0V; cut-in = 38.5 V
Other values can be set up if a FDC programming
kit is available.
Battery protection system
9FRCC.PI.045.A1.02

Protections and alarms
GD30FDC is electronically protected against a
number of possible dysfunctions and failures:
• Battery discharge.
• Fan over current: protects the compressor and
the electronic driver against fan over current
due to start or running overload, or short-circuit.
• Starting failure: if the running speed is not
achieved during the starting sequence, the unit
stops and retries the start up after one minute.
• Compressor overload: it operates when
the compressor speed drops below the set
up speed, or when the current drawn in is
excessive, and thus preventing the appliance
from operating under overload conditions that
may cause otherwise refrigeration overload or
compressor failure.
• Electronic driver overheat: if the temperature
of the electronic components of the control
becomes too high, an internal sensor will stop
the unit.
In case of overheating, one automatic attempt
to restart the compressor is allowed. In case of
battery protection, there is no limit of automatic
attempts to restart. In case of any other
protection occurring, there will be two automatic
attempts to re-start the compressor.
Once the sequence of automatic attempts to
restart the compressor is nished, the unit will
remain permanently unable to operate until
switched o and on again from the power
supply. The intervention of the thermostat during
the sequence of automatic restart attempts
interrupts and resets the sequence.
10 FRCC.PI.045.A1.02

Danfoss Commercial Compressors
is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications. With a wide range
of high quality and innovative products we help your company to find the best possible energy efficient solution that respects
the environment and reduces total life cycle costs.
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global
leaders in our business, and positioned us as distinct variable speed technology specialists. Today we operate from engineering
and manufacturing facilities spanning across three continents.
FRCC.PI.045.A1.02 - Danfoss Light Commercial Refrigeration Compressors made by Huayi © Danfoss | DCS (CC) | 2016.03
Our products can be found in a variety of applications such as rooftops, chillers, residential air conditioners,
heatpumps, coldrooms, supermarkets, milk tank cooling and industrial cooling processes.
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